Tuesday 17 July 2012

3.4 Planning department

The Planning department has to play a huge role with the production system of the factory. Mainly they have to deal with the merchandising department of the factory and find the capabilities of producing particular style in the production floor. They find the spaces of the factory production floor and allocate each order in an effective way.




The overall process of the merchandising department

3.3 Procurement department

                  This is the place where all the accessories need for the productions are purchased. They are mainly engaged on sourcing fabric and trims and negotiating with the supplier of goods for PO. The responsibility of supply of the required goods within a given time period, is with the procurement team and they have to communicate directly with the merchandising team. All the processes are within the T&A.
          

>.1.2 Sample room Planning

                             The planning section of the sample room is in charge of making the production plan for sewing and cutting processes. The importance of making a production plan for the sample room is to manage their sample producing process and the delivery of their goods in time to the buyer.
            The difference between the bulk production plan and the sample production plan is; that the sample room makes their production only for a day. But the bulk production plan is for a month.

·         Sample Requisition Sheet (SRF) ;
                 Sample Requisition Form is a document like the trim card, which includes all the trims and fabric samples of a particular sample. As these samples are still in the inquiry stage, the factory does not trend to buy accessories for making of samples. Except PP samples, they use factory sources to make sample and to prepare the SRF.
            Preparing of the SRF before the sample production starts is very important because the sample room needs fabric and trims references with their processing.
                   
            Preparing of the SRF before the sample production starts is very important because the sample room needs fabric and trims references with their processing.
                   
If we look at the production plan, first of all they should receive the SRF. The SRF should be handed over to the sample room on the day before the sewing date. The merchandising team prepares this SFR and there is a deadline to send SRF to sample planning officer. The cut off time is 3.00pm and after that time, the production planner starts create production plans for received SRFs.
                Before the sample room starts to sew sample for new style, they hold a meeting called The Risk Assignment Meeting. Some features of this meeting is same to the PP meeting and the main purpose of holding this meeting is for identifying the difficulties that they would have to face during the sampling process. Discussing the critical operations within the garment and give solutions for them are the main objectives of this RA meeting.

            The quality maintaining task is on the hands of tailors’ and no one is there to inspect the sewing process. Tailors have to submit a well finished garment to the quality section at the end of the sewing process. Then QC check is done for the finished samples’ quality.
            At the same time it shows how many samples for one tailor has to stitch.
            At the first time factory is placed an order for a new style and the sample room do a try-out sample. This is an internal process of the factory to take an idea about the garment and this is very important to the costing stage also. If it is a try out sample the pattern maker directly send his patterns to marker planer for marker drawing.
 Every developed patterns at the deferent stages are saved from their reference numbers in the sample room data base.
                                    Finally, patterns approved by the buyer are sent to the cutting department and they cut fabric by using these patterns. But at the costing and the ordering processes they don’t use approved patterns for marker drawing and they use pattern still at the developing stage.

>.1.2 Samples' types

The types of samples sent to buyer are varied according to the buyers’ nature. The factory always should be able to submit the sample whenever buyer asks for them.
There are some samples most commonly send to buyers and reason for sending them have described below.

Fit samples:
                        These are mainly sent to buyers for approvals of the measurements of the garment. After fit on garments to dummies, the buyer comments on the garment and mention what are the adjustments which should be done to the garment. When the comments are sent back to the garment supplier, the pattern maker changes the base pattern of the garment according to the buyer’s comments.
                                    The adjusted sample is once again sent to the buyer. If the second fit sample also rejected, the factory has to go even to the 3rd fit sample until it gets the approvals.

Strike off samples:
                                    These samples are sent to get approval on printed garment.
 The factory prints designs according to buyer’s instructions and then factory send a sample for the approvals. If the buyer not satisfied with placement of the print design, he comments on it and feedbacks sent to the garment supplier. He does the adjustment for the print design and once again a new sample is sent to the buyer for approvals. The garment supplier has to repeat the same thing if the sent samples are rejected.
             

3.2 Product development

The main responsibility of the development team is to handle the sampling process of the factory and deliver them to buyer in time.
If there are any changes have to be done to the garment, the development team is involved in this process and takes the necessary steps to fix it.

 3.2.1Sampling 


Monday 16 July 2012

<.3.2 Cut and Make cost (CM)

This value is calculated to estimate the cost of cut and make process of one garment. To calculate the C&M cost, we need two other factors, garment SMV and the CPM


SMV (Standard minute value)

                                                This term defines the time duration of a garment stitching process. The SMV for a garment is calculated in standard minutes and this value is calculated by the work-study of the sample room. There is special method to calculate this SMV. They use the GSD concept (General sewing data) to do this.
            The every operation of a garment is analyzed according to GSD and it gives time period to each operation of a garment. Once again these operations are analyzed according to the GSD codes and these codes describe the steps in an operation.

                               Furthermore;-
                                               
The time for taking panels, the time for matching panels, the time for putting panels under the MC foot, the time for stitching panels, the time for put aside the stitched panels and the time for taking new panels-


                        The GSD codes also some kind of above mentioned thing and these codes are given a standard time allocation. There would be more GSD codes within one operation and we can take the SMV of that operation by taking total of each code. The total SMV of the whole garment can be calculated by taking the total of all the operation within the garment.

CPM (Cost per minute)

This the factory running cost of per minute.